AUTOMATED AND ENERGY-EFFICIENT MAIL TRAY PROCESSING HOW POSTEN NORGE HAS USED THE

AUTOMATED AND ENERGY-EFFICIENT
MAIL TRAY PROCESSING
HOW POSTEN NORGE
HAS USED THE
CRISPLANT SORTER TO
REVOLUTIONISE ITS MAIL
CENTRE OPERATIONS,
REDUCING ENERGY COSTS
AND BOOSTING
PRODUCTIVITY
Posten Norge – the Norwegian Postal
Service – has the ambition of developing into the leading mail and logistics
corpor­ation in the Nordic region, in
tandem with becoming the world’s
most future-orien­ted mail and logistics
group.
A major elem­ent in this forward-thinking approach is the development of an
attractive workplace with a good
working environment for its 2,500
staff.
Case Study
Posten Norge
The Automatic
Tray Handling
System
environment for employees by considerably reducing the amount of manual
handling that staff have to carry out.
In line with Posten Norge’s
technologic­ally advanced ambitions,
this is first mail centre to install
Crisplant’s highly energy-efficient
LS-4000CB cross-belt sorter as part of
an automatic tray-handling p
­ rocess. As
a result of being powered by linear
synchronous motors, as opposed to
the conventional linear induction
­motors, the LS-4000CB achieves
energy savings of up to 75 percent.
After sorting, flats are filled into trays
according to the destination and manually
loaded onto conveyors for automatic
induction to the Automatic Tray Handling
System
An outstanding example of this
intention can be seen at Posten’s
Østlandstermin­alen mail centre in Oslo,
where a strategy was implemented to
reduce manual hand­ling and heavy lifts
and to create a single automated flow
through the operation by combining a
number of automated actions. To help
achieve this aim, at the end of 2008
Crisplant was awarded a contract to
supply and integrate an Automatic
(letter) Tray Handling System (ATHS)
based on a new energy-efficient
sortation/distribution system with auto
storage and robot palletising.
The completed project, known as the
­Automatic Tray Handling System
(ATHS), was put into operation in the
spring of 2010. It is capable of collecting, sorting, storing and palletising
more than 10,000 mail trays an hour,
setting a new stand­ard for short-flow,
high-accuracy mail handling. In
addition, it also achieves Posten
Norge’s aim of creating a safer working
2-3
At the mail centre, trucks arrive with
pre-sorted mail, which is taken to
different areas for processing depending on the type of item and required
process for small letters, flats and
small parcels. Letters are handled in
the letter sorting area where, after
sorting, they are filled into trays
according to the destination and
manually loaded onto conveyors for
automatic induction to the ATHS using
an LS-4000CB cross-belt sorter. Flats
are handled similarly in the flats sorting
area. Small parcels and large letters/
flats are handled in the multi-sorter
area where Crisplant has delivered and
installed another three cross-belt
sorters. There, items are loaded into
trays and automatically conveyed via
spiral conveyors for induction to the
ATHS.
AS A RESULT OF BEING
POWERED BY LINEAR
SYNCHRONOUS
MOTORS THE LS-4000CB
ACHIEVES ENERGY
SAVINGS OF UP TO 75
PERCENT
Having reached the ATHS, the trays are automatically
transported and sorted to a dynamic storage system
according to their destination and departure time.
Having reached the ATHS, the trays are
automatically transported and sorted
to a dynamic storage system according to their destination and depart­ure
time. The storage is a small-scale ‘high
bay’ storage system in four layers in
front of which the sorter loops in four
layers to feed all levels. The tray
storage has 248 lanes that hold 24
trays each. This ­dynamic storage is
actually a standard storage system
that, prior to this installation, was
typically used in large grocery distribution centres.
Crisplant developed and d
­ esigned the
software for the dynamic storage to
interface with direct feeding from the
ATHS sorter to all lanes as one of the
functionalities required by ­Posten
Norge’s ATHS concept.
In the dynamic storage, the Crisplant
Tray Management System at Østlandsterminalen accumulates the letter trays
in lines. When a line of letter trays is
ready for dispatch it is automatically
released from storage and conveyed to
robot cells for automated palletising.
There are four redundant robot cells,
each with two robots for high capacity
palletising. A fifth robot cell takes care
of automatic feeding of empty letter
trays and empty pallets. There is also
one area for manual palletising and one
of the cells takes care of automatic
feeding of pallets and empty letter
trays. Screens above the robot cell
indicate shipping destination and
routes when the pallet is ready for
dispatch, at which time it is moved by
forklift to the appropriate shipping
marshal area prior to loading on trucks
according to the destination shown on
the screens.
The contract is an extension of a
long-term partnership between
Crisplant and Posten Norge and further
reinforces Crisplant’s stature as a
leading global supplier of advanced
mail and parcel handling systems. The
new system is a success as it helps
Posten Norge to minimise health and
safety risks by significantly reducing
manual handling. In a
­ ddition, by
switching to a fully automated system,
staff relations are strengthened by
freeing operators to take on more
challenging multitask roles.
When a line of trays is ready for
dispatch it is automatically released from
storage and conveyed to robots for
automated palletising.
Case Study
Posten Norge
Automatic tray handling system
(ATHS) summary
The system integrates a fullyautomatic dynamic storage and
conveyor system. This will link all
of the receiving, preparation, letter,
flats, magazines and the rest of the
mail process handling and despatch
areas, as well as providing a dynamic
storage system for mail trays prior to
the delivery to the robotic palletizing
system. The complete installation is
managed by controls software written
and implemented by Crisplant.
•Sorter: LS-4000CB cross-belt,
484 m
•Capacity: 10.000 totes/h
•Inductions: 7
•Chutes: 124
•Tote size: Length 400 mm, width
300 mm, height 190 mm (max.)
•Dynamic storage capacity: 5.952
letter trays
•4 robot cells for palletising letter
trays. Total capacity: +6.000
totes/h
•1 robot cell for feeding of empty
trays and pallets.
10715-AA-700-V02-1EN-0811-SB-3243
Crisplant a/s
P.O. Pedersens Vej 10
DK-8200 Aarhus N
Phone: +45 87 41 41 41
[email protected]
www.beumergroup.com